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CQI-9Special Process: Heat Treat System Assessment

Version 2, Issue 8/07

Special Process: Heat Treat System Assessment

Facility Name:Address:

Phone Number: Type(s) of Thermal Processing at this Facility:Fax Number: Process Table A - Ferrous

CarburizingNumber of Heat Treat Employees at this Facility: Carbonitriding

Carbon CorrectionCaptive Heat Treater (Y/N): Neutral Hardening

Quench & TemperCommercial Heat Treater (Y/N): Austempering / Martempering

TemperingPrecipitation Hardening / Aging

Process Table B - FerrousNitriding (Gas)

Process Table C - AluminumAluminum Heat Treatment

Process Table D - FerrousInduction Heat Treating

Process Table E AnnealingNormalizingStress-Relieving

Current Quality Certification(s):

Date of Re-assessment (if necessary):

Personnel Contacted:Name: Title: Phone: Email:

Auditors/Assessors:Name: Company: Phone: Email:

Number of "Not Satisfactory" Findings:

Number of "Needs Immediate Action" Findings:

Number of "Fail" Findings in the Job Audit(s):

Date of Assessment:

Date of Previous Assessment:

Ferritic-Nitrocarburizing (Gas or Salt)




Assessment

Question Requirements and Guidance Objective Evidence N/A Satisfactory

Section 1 - Management Responsibility & Quality Planning

1.1

1.2

1.3

Question Number

Not Satisfactory

Needs Immediate Action

Is there a dedicated and qualified heat treat person on-

site?

To ensure readily available expertise, there shall be a dedicated and qualified heat treat person on site. This individual shall be a full-time employee and the position shall be reflected in the organization chart. A job description shall exist identifying the qualifications for the position including metallurgical and heat treat knowledge. The qualifications shall include a minimum of 5 years experience in heat treat operations or a combination of a minimum of 5 years of formal metallurgical education and heat treat experience.

Does the heat treater perform advanced quality planning?

The organization shall incorporate a documented advance quality planning procedure. A feasibility study shall be performed and internally approved for each part. Similar parts can be grouped into part families for this effort as defined by the organization. After the part approval process is approved by the customer, no process changes are allowed unless approved by the customer. The heat treater shall contact the customer when clarification of process changes is required. This clarification of process changes shall be documented.

Are heat treat FMEA's up to date and reflecting current

processing?

The organization shall incorporate the use of a documented Failure Mode and Effects Analysis (FMEA) procedure and ensure the FMEA's are updated to reflect current part quality status.The FMEA shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and all key heat treat process parameters as defined by the organization. A cross-functional team shall be used in the development of the FMEA. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the FMEA.




Assessment

Question Requirements and Guidance Objective Evidence N/A SatisfactoryQuestion Number

Not Satisfactory


1.4Are heat treat process control plans up to date and reflecting

current processing?

The organization shall incorporate the use of a documented Control Plan procedure and ensure the Control Plans are updated to reflect current controls.The Control Plans shall be written for each part or part family or they may be process-specific and written for each process. In any case, they shall address all process steps from part receipt to part shipment and identify all equipment used and all key heat treat process parameters as defined by the organization. A cross-functional team, including a production operator, shall be used in the development of Control Plans, which shall be consistent with all associated documentation such as work instructions, shop travelers, and FMEA's. All special characteristics, as defined by the organization and its customers, shall be identified, defined, and addressed in the Control Plans. Sample sizes and frequencies for evaluation of process and product characteristics shall also be addressed consistent with the minimum requirements listed in the Process Tables, Sections 3.0 and 4.0.




Assessment


Not Satisfactory


1.5

1.6

Are all heat treat related and referenced specifications current and available? For example: SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler.

To ensure all customer requirements are both understood and satisfied, the organization shall have all related heat treat and customer referenced standards and specifications available for use and a method to ensure that they are current. Such standards and specifications include, but are not limited to, those relevant documents published by SAE, AIAG, ASTM, General Motors, Ford, and DaimlerChrysler. The organization shall have a process to ensure the timely review, distribution, and implementation of all customer and industry engineering standards / specifications and changes based on customer-required schedule. Timely review should be as soon as possible and shall not exceed two working weeks. The organization shall document this process of review and implementation, and it shall address how customer and industry documents are obtained, how they are maintained within the organization, how the current status is established, and how the relevant information is cascaded to the shop floor within the two-week period. The organization shall identify who is responsible for performing these tasks.

Is there a written process specification for all active

processes?

The heat treater shall have written process specifications for all active processes and identify all steps of the process including relevant operating parameters. Examples of operating parameters include process temperatures, cycle times, load rates, atmosphere or gas flow settings, belt speeds, quench agitation speeds, etc. Such parameters shall not only be defined, they shall have operating tolerances as defined by the organization in order to maintain process control. All active processes should have a written process specification. These process specifications may take the form of work instructions, job card, computer-based recipes, or other similar documents.




Assessment


Not Satisfactory


1.7

1.8

Has a valid product capability study been performed initially and after process equipment has been relocated, or had a

major rebuild?

To demonstrate each process is capable of yielding acceptable product the organization shall perform product capability studies for the initial validation of each process, after relocation of any process equipment, & after a major rebuild of any equipment. The organization shall define what constitutes a major rebuild. Initial product capability studies shall be conducted for all heat treat processes per furnace line defined in scope of work & in accordance with customer requirements. A furnace line may include a combination of equipment that is integrated in the performance of a heat treatment process, e.g., hardening, quenching, and tempering. Capability study techniques shall be appropriate for the heat treat product characteristics, e.g., tensile strength, case depth, hardness. Any specific customer requirements shall be met, in the absence of customer requirements, the organization shall establish acceptable ranges for measures of capability. An action plan shall exist to address the steps to followed in case capability indices fall outside customer requirements or established ranges.

Does the heat treater collect and analyze data over time,

and react to this data?

The analysis of products and processes over time can yield vital information for defect prevention efforts. The organization shall have a system to collect, analyze, and react to product or process data over time.Methods of analysis shall include ongoing trend or historical data analysis of product or process parameters. The organization shall determine which parameters to include in such analysis.




Assessment


Not Satisfactory


1.9

1.10

1.11

1.12

Is management reviewing the heat treat monitoring system

every 24 hours?

Management shall review the furnace monitoring systems at intervals not to exceed 24 hours. The heat treat monitoring system includes but is not limited to temperature strip charts, atmosphere strip charts, computer data logs, furnace and operator logs, etc.The management review shall include efforts to detect out-of-control conditions or alarm conditions. The process of reviewing the furnace data shall be documented and this requirement also applies to computerized data.

Are internal assessments being completed on an annual

basis, at a minimum, using AIAG HTSA?

The organization shall conduct internal assessments on an annual basis, at a minimum, using the AIAG HTSA.

Is there a system in place to authorize reprocessing and is

it documented?

The quality management system shall include a documented process for reprocessing that shall include authorization from a designated individual.The reprocessing procedure shall describe product characteristics for which reprocessing is allowed as well as those characteristics for which reprocessing is not permissible.Any reprocessing activity shall require a new processing control sheet issued by qualified technical personnel denoting the necessary heat treat modifications. Records shall clearly indicate when and how any material has been reprocessed. The Quality Manager or a designee shall authorize the release of reprocessed product.

Does the Quality Department review, address, and

document customer and internal concerns?

The quality management system shall include a process for documenting, reviewing, and addressing customer concerns and any other concerns internal to the organization. A disciplined problem-solving approach shall be used.




Assessment


Not Satisfactory


1.13

1.14

1.15

1.16

Is there a continual improvement plan applicable

to each process defined in the scope of the assessment?

The heat treater shall define a process for continual improvement for each heat treat process identified in the scope of the HTSA. The process shall be designed to bring about continual improvement in quality and productivity. Identified actions shall be prioritized and shall include timing (estimated completion dates). The organization shall show evidence of program effectiveness.

Does the Quality Manager or designee authorize the

disposition of material from quarantine status?

The Quality Manager is responsible for authorizing and documenting appropriate personnel to disposition quarantine material.

Are there procedures or work instructions available to the

heat treat personnel that define the heat treating

process?

There shall be procedures or work instructions available to heat treat personnel covering the heat treating process. These procedures or work instructions shall include methods of addressing potential emergencies (such as power failure), equipment start-up, equipment shut-down, product segregation (See 2.8), product inspection, and general operating procedures. These procedures or work instructions shall be accessible to shop floor personnel.

Is management providing employee training for heat

treating?

The organization shall provide employee training for all heat treating operations. All employees, including backup and temporary employees, shall be trained. Documented evidence shall be maintained showing the employees trained and the evidence shall include an assessment of the effectiveness of the training. Management shall define the qualification requirements for each function, and ongoing or follow-up training shall also be addressed.




Assessment


Not Satisfactory


1.17

1.18

1.19

Is there a responsibility matrix to ensure that all key

management and supervisory functions are performed by

qualified personnel?

The organization shall maintain a responsibility matrix identifying all key management and supervisory functions and the qualified personnel who may perform such functions. It shall identify both primary and secondary (backup) personnel for the key functions (as defined by the organization). This matrix shall be readily available to management at all times.

Is there a preventive maintenance program? Is maintenance data being

utilized to form a predictive maintenance program?

The organization shall have a documented preventive maintenance program for key process equipment (as identified by the organization). The program shall be a closed-loop process that tracks maintenance efforts from request to completion to assessment of effectiveness. Equipment operators shall have the opportunity to report problems, and problems shall also be handled in a closed-loop manner.Company data, e.g., downtime, quality rejects, first-time-through capability, recurring maintenance work orders, and operator-reported problems, shall be used to improve the preventive maintenance program. Furnaces and generators shall be scheduled for burn-out at frequencies determined by the organization (see Section 1 of the Process Tables).Maintenance data shall be collected and analyzed as part of a predictive maintenance program.

Has the Heat Treater developed a critical spare part list and are the parts available

to minimize production disruptions?

The heat treater shall develop and maintain a critical spare parts list and shall ensure the availability of such parts to minimize production disruptions.




Assessment


Not Satisfactory


Section 2 - Floor and Material Handling Responsibility

2.1

2.2

2.3

Does the facility ensure that the data entered in the

receiving system matches the information on the customer's

shipping documents?

It is critical that all customer requirements and lot identification be adequately transferred to internal heat treat documents. The facility shall ensure that the data entered in the receiving system match the information on the customer's shipping documents. Documented processes and evidence of compliance shall exist, e.g., shop travelers, work orders, etc. Sometimes the material received does not precisely correspond to customer shipping documents. The facility shall have a detailed process in place to resolve receiving discrepancies.The requirements stated above also apply to captive heat treat departments. This process refers to receiving and shipping the parts in and out of the heat treat department.

Is product clearly identified and staged throughout the

heat treat process?

Procedures for part and container identification help to avoid incorrect processing or mixing of lots. Appropriate location and staging within the facility also help to ensure that orders are not shipped until all required operations are performed. Customer product shall be clearly identified and staged throughout the heat treat process. Non-heat treated, in-process, and finished product shall be properly segregated and identified. All material shall be staged in a dedicated and clearly defined area.

Is lot traceability and integrity maintained throughout all

processes?

Out-going lot(s) shall be traceable to the incoming lot(s).The discipline of precisely identifying lots and linking all pertinent information to them enhances the ability to do root cause analysis and continual improvement.




Assessment


Not Satisfactory


2.4

2.5

2.6

Are procedures adequate to prevent movement of non-conforming product into the production system?

The control of suspect or non-conforming product is necessary to prevent inadvertent shipment or contamination of other lots. Procedures shall be adequate to prevent movement of non-conforming product into the production system. Procedures shall exist addressing proper disposition, product identification, and tracking of material flow in and out of the hold area. A non-conforming hold area shall be clearly designated to maintain segregation of such material.

Is there a system to identify trap points in the entire heat

treat process to reduce risk of mixed parts (inappropriate,

non-heat treated, or improperly heat treated

parts)?

Heat-treating furnaces and other processing equipment contain areas that have a risk of trapping or holding parts. Such trapping of parts can lead to damage, improperly processed parts or lot mixing/contamination. A system shall exist to identify trap points in the entire heat treat process to reduce risk of mixed parts (inappropriate, non-heat treated, or improperly heat treated parts). The heat treater shall have documented procedures to identify and monitor trap points for each process/equipment. Monitoring of potential trap points shall occur for every part changeover.

Are containers free of inappropriate material?

Containers handling customer product shall be free of inappropriate material. After emptying and before re-using containers, containers shall be inspected to ensure that all parts and inappropriate material have been removed. The source of inappropriate material shall be identified and addressed. This is to ensure that no nonconforming heat treated parts or inappropriate material contaminate the finished lot.




Assessment


Not Satisfactory


2.7

2.8

2.9

Is furnace loading specified, documented and controlled?

Furnace loading parameters shall be specified, documented, and controlled. Examples include feed rate, belt speed, number of parts per fixture, and load weight. Refer to Process Tables, Section 3.0, for frequency of checks.

Are operators trained in material handling,

containment action and product segregation in the

event of an equipment emergency including power

failure?

Unplanned or emergency downtime greatly raises the risk of improper processing. Operators shall be trained in material handling, containment action, and product segregation in the event of an equipment emergency including power failure. Training shall be documented. Work instructions specifically addressing potential types of equipment emergencies and failures shall be accessible to and understood by equipment operators. These instructions shall address containment actions related to all elements of the heat-treating process, e.g., loading, austentizing, quenching, tempering.

Is the handling, storage and packaging adequate to

preserve product quality?

Handling, storage, and packaging shall be adequate to preserve product quality. The heat treater’s furnace loading system, in-process handling, and shipping process shall be assessed for risk of part damage or other quality concerns.Some equipment includes conveyors and other moving components that may not be able to handle all part configurations. Other practices such as stacking of overloaded containers can also increase the risk of part damage.




Assessment


Not Satisfactory


2.10

2.11

Are plant cleanliness, housekeeping, environmental

and working conditions conducive to control and

improved quality?

Plant cleanliness, housekeeping, environmental, and working conditions shall be conducive to controlling and improving quality. The heat treater should evaluate such conditions and their effect on quality. A housekeeping policy shall be clearly defined and executed. The facility shall be reviewed for conditions that are detrimental to quality processing such as loose parts on floor, oil around quench tanks, inadequate plant lighting, smoke, etc.

Are parts free from contaminants that would be

detrimental to the heat treatment of the product?

Many heat-treated parts are subjected to surface finish or appearance operations such as plating or coating after heat treatment. Parts shall be free from contaminants that are detrimental to subsequent processes or the product. Pre-wash (if applicable) and post-wash parameters shall be monitored and documented. Oils and other contaminants or residues can be difficult to remove once subjected to the heat treatment process. Review the chemical supplier’s recommendation for cleaning the system. Parts shall be free of rust, burrs, chips, detrimental amounts of drawing compound, cutting fluids, rust preventing oils, lubricants, etc., prior to heat treat. Note: Refer to the appropriate heat treater's requirements and specifications to determine acceptability. Refer to Process Table, Section 5.0, for frequency of checking washer solutions.




Assessment


Not Satisfactory


2.12

2.13

2.14

2.15

Is the quenching system monitored, documented, and

controlled?

The quenching system shall be monitored, documented, and controlled. The temperature, agitation, level, concentration (if applicable), time in the quenchant, and additions shall be controlled to the heat treater's specifications. Refer to Process Tables, Sections 3.0 and 5.0, for frequency of checks. Computer-monitoring equipment, with alarms and alarm logs, satisfy the verification requirement. Quench delay tolerance and alarm is required for furnaces with integral quench tanks. Temper delay time shall be specified by the heat treater for parts that are quenched and tempered, e.g., carburizing, carbonitriding, neutral hardening, solution treating and aging.

Is soluble oil or other rust preventive monitored and controlled if applicable?

Parts are often dipped in or sprayed with rust preventive solutions immediately after the heat treating process. Soluble oil solutions or other rust preventive solutions shall be monitored and controlled, if applicable. The heat treater shall have and maintain documented tolerances for the solutions. Refer to Process Tables, Section 5.0, for frequency of checks.

Are process control parameters monitored per frequencies specified in

Process Tables?

Process control parameters shall be monitored per frequencies specified in Process Tables. Refer to Process Tables, Section 3.0. Computer monitoring equipment with alarms and alarm logs satisfy the verification requirement. A designated floor person shall verify the process parameters, e.g., by initialing a strip chart or data log. Management review is required per Question 1.9.

Are In-Process / Final Test Frequencies performed as

specified in Process Tables?

In-Process / Final Test Frequencies shall be performed as specified in Process Tables. Refer to Process Tables, Section 4.0.




Assessment


Not Satisfactory


2.16 Is product test equipment verified?

Product test equipment shall be verified. Test equipment shall be verified/calibrated per applicable customer-specific standard or per an applicable consensus standard such as those published by ASTM, DIN, EN, ISO, JIS, NIST, SAE etc. Verification/calibration results shall be internally reviewed, approved, and documented. Refer to Process Tables, Section 1.0, for frequency of checks.




Assessment


Not Satisfactory


Section 3 - Equipment

3.1

3.2

3.3

3.4

3.5

3.6

Do furnaces, generators, and quench systems have proper process control equipment?

The heat-treat furnaces, generators, and quench systems shall have proper process controls and related equipment. Examples include temperature, carbon potential/dew point, gas flows, quench monitoring system including agitation, temperature control and quenching oil analysis, etc. as listed in the applicable Process Tables, Section 1.0.

Are process equipment calibrations and/or verification certified, posted, and current?

The calibration and certification of the process equipment shall be checked at regular specified intervals. Refer to the applicable Process Tables, Sections 1.0 and 2.0, for equipment calibration or certification time tables.

Are thermocouples & protection tubes checked or

replaced per Process Tables?

The thermocouples and protection tubes shall be checked or replaced in compliance to a preventive maintenance schedule. Refer to the applicable Process Tables, Section 2.0.

Are temperature uniformity surveys performed per

requirements in Process Tables?

Temperature uniformity surveys shall be conducted per the requirements in the applicable Process Tables, Section 2.0. The frequency reductions allowed in AMS 2750D are not allowed under this document. Certain furnace designs, e.g., rotary retorts preclude direct temperature profiles. Alternate test methods per AMS 2750D 3.5.15 are acceptable for furnaces where temperature uniformity studies are not possible.

Is the variation of the furnace controlled thermocouple from

set point within the requirements in the Process

Table?

The variation between the furnace-control thermocouple and the set point temperature shall be within the limits defined in the applicable Process Tables, Section 2.0. This does not apply to the first zone of a multi-zone continuous furnace.

Are the process & equipment alarm checks being tested

quarterly or after any repair or rebuild?

The heat treater shall have a list of heat treat process and equipment alarms. These alarms shall be independently tested quarterly at a minimum, and after any repair or rebuild. These checks shall be documented.




Assessment


Not Satisfactory


3.7

Are generators and furnace atmospheres continuously monitored, automatically

controlled, and documented?

Generator and furnace atmosphere carbon potential/dew point shall be continuously monitored, automatically controlled, and documented. This requirement is specific to Process Table 1, Sections 1.0 and 3.0, for carburizing, carbonitriding, and neutral hardening. Continuous monitoring and automatic control of the carbon potential/dew point is required for all generators and atmosphere furnaces except rotary retort and shaker furnaces that preclude in situ control and monitoring. For rotary retort and shaker furnaces, the method described in AMS 2750D 3.5.15..2 "Property Surveys" shall be used to ensure adequate control of the furnace atmosphere. If generators are not used, the flow rates of the supplied atmosphere gases shall be monitored and controlled. The assessor shall verify the effectiveness of the atmosphere control system per customer requirements, the heat treater’s control plan, and internal procedures.

The atmosphere control system shall maintain the atmosphere dew point/carbon potential set point within the parameters specified in the control plan or internal procedures. The heat treater shall have a back-up method of checking the carbon potential/dew point. Examples are dew point, electrical wire resistance, gas analysis, shim stock, carbon bar, etc. The automatic and continuous atmosphere control system shall consist of sensors such as oxygen probes or on-line Infrared (IR) gas analysis. See Process Table A, Sect. 3.0 for verification frequencies.




Assessment


Not Satisfactory


3.8

When the back-up verification check of the atmosphere does not agree or correlate within

pre-established limits with the primary control method

(carbon potential/dew point reading), is correlation of the

carbon-bearing atmosphere to the primary control method re-

established?

This issue is specific to Process Table 1, carburizing, carbonitriding, and neutral hardening. When the back-up verification check of the atmosphere does not agree or correlate within pre-established limits with the primary control method (carbon potential/dew point reading), the heat treater shall resolve the out-of-limit discrepancy. The back-up atmosphere monitoring system reading and the automatically controlled atmosphere dew point/carbon potential reading shall be maintained within the correlation limits specified in the control plan or internal procedures. These range tolerances vary with the specific heat treat process and the equipment used. The heat treater shall make appropriate technical adjustments and corrections and then re-establish/demonstrate the correlation of the actual atmosphere carbon potential/dew point reading to the primary control and back-up atmosphere reading. The range tolerances for correlation between the two readings shall be in the control plan or internal procedures. The back-up carbon potential/dew point reading shall be established using one or more of the following methods: • Carbon bar or slug• Shim stock• 3-gas analyzer• Dew point• Hot wire resistance




Assessment


Not Satisfactory


3.9

3.10

3.11

Are all ammonia lines equipped with quick

disconnects or a three valve fail safe vent system?

All ammonia lines to furnaces shall be equipped with quick disconnects or a three-valve fail-safe vent system. Normal valves may allow ammonia to leak through even when they are closed. This can be undesirable and detrimental in heat treat processes not specifying/requiring ammonia.• A quick disconnect shall be present in any ammonia line going to a furnace. This line shall be disconnected after carbonitriding (or any other process using ammonia) before another heat treating operation not specifying/using ammonia begins.• An alternative three-valve ammonia "fail-safe" vent system is permitted. See the definition “Three Valve Fail-Safe Vent” and diagram in the glossary.• Documentation shall show when ammonia lines are disconnected for non-ammonia bearing atmosphere processes.

For fasteners and small metal parts, is a minimum of 3 hours

allocated for an oxidizing burn-out prior to processing

product not requiring ammonia?

This is applicable to fasteners and small metal parts. The heat treater shall perform a minimum 3 hours oxidizing burn-out prior to processing product not requiring ammonia as an addition. Ammonia pick-up can be undesirable in parts and heat treat processes not specifying/requiring ammonia as an addition. Log book, data logger, or other records shall document the actual oxidizing burn-out time and that sufficient time has been allocated to remove ammonia from the furnace prior to processing parts in heat treat processes not specifying ammonia.

Do all atmosphere furnaces and generators have flow scopes or flow meters for all gases?

All atmosphere furnaces and generators (output trim/adjustment gas) shall have flow scopes or flow meters for all gases. Flow scopes and meters shall be periodically serviced per the heat treater's preventive maintenance program. Cleaning and proper re-assembly procedures shall be documented.




Assessment


Not Satisfactory


3.12

3.13

3.14

For threaded fasteners, are all continuous belt furnaces equipped with sight glass

inspection ports and infrared pyrometers at discharge end of the hardening furnace?

Infrared temperature pyrometers are required at the exit end of continuous belt furnaces running threaded fasteners to monitor for under temperature parts. The temperature alarm shall be within 28C (50F) of the furnace set point temperature. Results shall be strip charted or continuously data logged. Infrared (IR) units shall be calibrated annually at a minimum and certified. All sight glasses shall be cleaned per the preventive maintenance schedule.

Is salt chemistry in the austenitizing salt bath

monitored?

Applicable to ferritic-nitrocarburizing, austempering, and neutral hardening in salt.The heat treater shall check the salt chemistry in the austentizing salt bath, or part decarburization, daily. Refer to the applicable Process Tables, Section 3.0, for frequency of checks.

Is the quenching medium analyzed?

The heat treater shall periodically have the quenching medium analyzed for specific quenching characteristics, e.g., cooling curve, water content, salt concentration, as specified in the applicable Process Tables, Section 5.0.• The quench media characteristic tolerances shall be specified by the quench medium supplier or the heat treater.• Analysis shall be reviewed for conformance by the heat treater. This review shall be documented.




Assessment


Not Satisfactory


FOR INDUCTION HEAT TREATING

3.15

3.16

3.17

3.18 Is quench system automatic?

3.19

Is the positioning of each part being controlled?

A method to detect proper part position, such as the use of proximity switches, optical sensors, mechanical probes, etc., is required for each part.

Does the heat treater control the energy or power for each part?

The heat treater shall control the energy or power for each part.• A signature monitor for each machine is preferred. A signature monitor gives the energy unit (voltage, kilowatt, etc.) vs. time or distance (for scanning systems).• An energy monitor or equivalent is acceptable if approved by the authorized customer representative.

Does the supplier have a coil management system? Coil refers to the heating coil and the quench plenum.

The heat treater shall have a coil management system. Coil refers to the heating coil and the quench plenum.• Spare coils for each part shall be available on-site.• Coils shall conform to the approved original design.• Engineering change approval from the customer is required whenever the coil design is changed.

The quench system shall be an automatic operation. No manual quenching is allowed unless specifically approved by the authorized customer representative. Quenching shall be automatically initiated and controlled.

Does each lot of parts have first piece set-up?

The heat treater shall perform first piece set-up for each lot of parts



Section 4 - Job Audit

Job Identity:Customer:

Shop Order Number:Part Number:

Part Description:Material:

Heat Treat Requirements:

Question # Job Audit Question

4.1

N/A

4.2 1.5 N/A

4.3

4.4

4.5 2.1

4.6

4.7

RelatedHTSA Question #

Customer or Internal Requirement

Job (Shop) Order or Reference Documentation

Requirement

Actual Condition (Objective Evidence)

Pass / Fail / N/A

Are contract review, advance quality planning, FMEA, control plans, etc., performed by qualified individuals?

1.21.31.4

1.17

Does the heat treat facility have the customer specifications for the part?

Is a shop traveler created to meet customer requirements?

1.62.1

Is material identification (part numbers, lot numbers, heat numbers, contract numbers, etc.) maintained throughout the heat treat process?

2.22.32.4

Is there documented evidence of Receiving Inspection?

Are the Loading / Racking requirements identified?

1.62.72.9

Is the proper recipe or process specification (cycle times, temperature, atmosphere, etc.) used? Refer to Process Tables, Section 3.0, for specific parameters. List parameters that were verified in this audit in the spaces provided below.

1.51.62.1

2.142.15








Question # Job Audit Question RelatedHTSA Question #



Requirement


Pass / Fail / N/A

4.8 2.15

4.8.1 Requirement: (1)Test Method:Test frequency or quantity:Selection of samples:Specification:



4.8.4 Requirement: (4)Test Method:Test frequency or quantity:Selection of samples:

What are the product inspection requirements?











Requirement


Pass / Fail / N/A

Specification:











Requirement


Pass / Fail / N/A

Operator or Inspector Responsibilities4.9

4.10

4.11

4.12

4.13 1.11

4.14

4.15 1.17

4.16

Were appropriate process steps signed off?

1.42.22.3

2.14

Were all inspection steps, as documented in the control plan performed?

1.21.4

Were steps/operations performed that were not documented in the control plan?

1.21.41.6

If additional steps were performed, were they authorized?

1.21.41.6

1.111.17

Does the governing specification allow reprocessing or rework?

If the order was certified, did the certification accurately reflect the process performed?

2.142.15

Was the certification signed by an authorized individual?

Are the parts and containers free of inappropriate objects or contamination?

2.62.11











Requirement


Pass / Fail / N/A

Packaging Requirements4.17 2.9

4.18 2.9

Shipping Requirements4.19 Were the parts properly identified?

4.20

Are packaging requirements identified?

Are parts packaged to minimize mixed parts (for example, parts packed over height of container)?

2.32.9

Were the containers properly labeled?

2.32.9



Item # Category/Process Steps Generators

1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTSA1.1 Yes Yes Yes

A1.2 Yes Yes

A1.3 1.18 Yes Yes Yes

A1.4 3.2 Yes Yes -----

A1.5 3.2 ----- ----- -----

A1.6 3.2 ----- ----- -----

A1.7 3.2 ----- ----- -----

A1.8 3.2 Yes Yes Yes

A1.9 2.16 ----- ----- -----

A1.10 2.16 ----- ----- -----

A1.11 3.2 ----- ----- -----

PROCESS TABLE A - Carburizing / Carbonitriding / Carbon Correction / Neutral Hardening / Austempering / Martempering / Tempering / Precipitation Hardening - Aging

All requirements given below are subordinate to customer specific requirements.

The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.

* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.** Does not apply to furnaces operating below 760C (1400F).----- indicate "not applicable".

Related HTSA Question #

Batch Furnace

ContinuousFurnace *

3.13.7

All furnaces, generators and quench systems shall have temperature indicating instruments.

3.13.7

Continuous strip charts and/or data loggers are required for temperature and carbon monitoring unit, e.g., dew point, oxygen probe, IR gas analyzer, etc.

Yes

A program for furnace and generator burnout is required (applies to carbon bearing atmospheres).

Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.

Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, shall be calibrated annually at a minimum.

Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use.

Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum.

Oxygen probe controllers shall be calibrated quarterly at a minimum.

All hardness test equipment (for each scale used) shall be calibrated semi-annually minimum, and verified daily minimum per the applicable ASTM standard.

Files shall be verified daily (or prior to use) with provers per SAE J864.

Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified daily (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.









Batch Furnace

ContinuousFurnace *

2.0 PYROMETRYA2.1 Yes Yes Yes

A2.2 Yes Yes Yes

A2.3 Yes Yes Yes

A2.4 3.4 Yes -----

A2.5 3.5 Yes -----

3.23.3

Thermocouples and calibration of thermocouples shall conform to AMS 2750D.

3.23.3

Instrument Calibration per AMS 2750D shall be quarterly at a minimum.

Frequency reductions per AMS 2750D are not allowed.

3.23.3

CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C). (1) The CTS shall be within an operating temperature range of +/- 5C (or +/-10F) of the CTTS. This check shall be performed monthly. (2) Within the operating temperature range the difference between the CTS and R-T/C readings shall be no more than +/- 1C (or +/-2F) as determined at the time of the most recent temperature uniformity survey. This check shall be performed weekly. Any actions to correct a failing reading or validate a test result shall be documented. Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.

Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed every two years at a minimum. Protection Tubes shall be visually checked at the same frequency as thermocouples.

Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be annual and after major rebuild.

Temperature uniformity tolerance for hardening furnaces shall be +/- 14 C (or +/- 25 F). Temperature uniformity tolerance for tempering furnaces shall be +/- 11 C (or +/- 20 F).

Minimum and maximum temperature ranges shall be tested per AMS 2750D. Exception: If the operating range of the Qualified Work Zone is equal to or less than 85 C (153 F) then only one temperature is required to be tested. The temperature shall be within the operating range of the Qualified Work Zone.


Yes - In Qualified Work Zone

Recorded temperature(s) for austentizing processes shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).










Batch Furnace

ContinuousFurnace *

A2.6 3.5 Yes -----

A2.7 3.2 -----

Recorded temperature(s) for tempering and precipitation hardening processes shall be controlled within +/- 6C (or +/- 10F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).


Infrared pyrometers shall be calibrated to a black body furnace annually.









Batch Furnace

ContinuousFurnace *

3.0 PROCESS MONITOR FREQUENCIESA3.1 Monitor primary temperature control instrument(s). Each Shift

A3.2 Monitor generator atmospheres. ----- ----- Continuous

A3.3 Monitor primary furnace atmosphere control(s)**. -----

A3.4 Daily Daily Daily

A3.5 Daily Daily -----

A3.6 Quench Media Process Parameters- Temperature -----

- Quench Level Daily Daily -----

- Agitation -----

A3.7 Monitor time in furnace, cycle time or belt speed. Each batch -----

A3.8 Monitor load size or fixturing or loading rate as applicable. Each batch -----

A3.9 Each batch -----

1.42.14

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

1.42.143.7

1.42.143.7

Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

1.42.143.7

Verify primary atmosphere control method by back-up method**.

1.42.143.13

For austentizing salt baths: Salt chemistry (soluble oxides) or decarburization on the parts shall be checked daily.

1.42.12 Each batch or

continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.

- Daily visual check is required.

- Monitor each load in the absence of an alarm system.


- Monitor every 2 hours in the absence of an alarm system.

1.42.14

Twice/shift & after any change in the belt speed.

1.42.7

Twice/shift & after any change in loading rate.

1.42.12

Quench Delay Time -Alarm system shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.

Each basket for pusher-type continuous furnaces. Not applicable for belt furnaces.









Batch Furnace

ContinuousFurnace *

4.0 IN-PROCESS/FINAL TEST FREQUENCIES

A4.1 Microstructure Daily per furnace Daily per furnace -----

A4.2 Surface hardness Each batch Every 2 hours minimum -----

A4.3 Core hardness (when specified) Each batch Every 4 hours -----

A4.4 Case depth (when specified) Each batch Every 4 hours -----

5.0 QUENCHANT AND SOLUTION TEST FREQUENCIESA5.1 Polymer Quench Media

- Concentration Daily Daily ------ Quenchability Check; e.g., cooling curve, viscosity, or titration Every six months Every six months -----

A5.2 Water Quench Media- Suspended solids Every six months Every six months -----

A5.3 Salt Quench Media- Analysis & Contaminants Every six months Every six months -----

A5.4 Brine or Caustic Quench Media Daily Daily -----

- Suspended solids Every six months Every six months -----A5.5 Oil Quench Media

Quarterly Quarterly -----

A5.6 2.13 Rust Preventive - Soluble Oil- Concentration 2x / week 2x / week -----

A5.7 2.11 Washers- Concentration of cleaner Daily Daily -----

Each shift Each shift -----

1.42.151.4

2.151.42.151.4

2.15

2.123.14

2.123.142.123.142.123.14 - Concentration and/or Specific

Gravity.

2.123.14 - Water content, suspended solids,

viscosity, cooling curve, total acid, and flash point.

- Temperature of solution (required if temperature is specified to be above ambient temperature).



Item # Category/Process Steps Generators Salt Bath

1.0

B1.1 Yes Yes Yes Yes

B1.2 Yes Yes

B1.3 1.18 Yes Yes Yes -----

B1.4 ----- ----- ----- Yes

B1.5 3.2 Yes Yes ----- -----

B1.6 3.2 ----- ----- ----- -----

B1.7 2.16 ----- ----- ----- -----

B1.8 2.16 ----- ----- ----- -----

B1.9 3.2 ----- ----- ----- -----

PROCESS TABLE B - Nitriding (Gas) and Ferritic-Nitrocarburizing (Gas or Salt)



* Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

PROCESS AND TEST EQUIPMENT REQUIREMENTS

3.13.7

All furnaces, generators and quench systems shall have temperature indicating instruments.

3.13.7


Yes Yes - For

temperature only

A program for furnace and generator burnout is required. Not required for retort gas nitriding.

3.123.13

For austentizing salt baths: Salt chemistry (soluble oxides) or decarburization on the parts shall be checked daily.Furnace weigh scales shall be verified quarterly and calibrated annually at a minimum.

Dew pointers and gas analyzers, used to verify proper atmosphere in furnaces, shall be calibrated annually at a minimum.


Files shall be verified daily (or prior to use) with provers per SAE J864.









Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

2.0 PYROMETRY B2.1 Yes Yes Yes Yes



3.23.3


3.23.3



3.23.3

CQI-9 requires a comparative check of the control temperature sensor (CTS) in the Qualified Work Zone to a (1) calibrated test temperature sensor (CTTS) or, (2) resident thermocouple (R-T/C).

(1) The CTS shall be +/- 5C (or +/- 10F) of a CTTS at the operating temperature range; this checked shall be performed monthly.

(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the most recent temperature uniformity survey; this checked shall be performed weekly.

Any actions to correct a failing reading or validate a test result shall be documented.

Additionally, Type K and N thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed annually at a minimum. Type K and N thermocouples shall be checked quarterly for equipment operating below 760C (1400F) and changed every two years at a minimum.

Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed every two years at a minimum.

Protection Tubes shall be visually checked at same frequency as thermocouples.








Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

B2.4 3.4 Yes ----- Yes

B2.5 3.5 Yes ----- Yes

B2.6 3.2


Temperature uniformity tolerance shall be +/- 9 C (15 F).




Recorded temperature(s) shall be controlled within +/- 9C (or +/- 15F) of the set point as evidenced by continuous recording pyrometers. Furnace temperature shall be controlled with soak times starting at the lower tolerance limit (as defined above).


Infrared pyrometers shall be calibrated to a black body furnace annually .








Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

3.0 PROCESS MONITOR FREQUENCIESB3.1 Monitor primary temperature control instrument(s). Each Shift

B3.2 Monitor generator atmospheres, if applicable. ----- ----- Continuous -----

B3.3 Monitor primary furnace atmosphere control(s). ----- Daily

B3.4 Every 4 hours Daily N/A

B3.5 Gas ratios for ferritic nitrocarburizing shall be checked. Each batch

B3.6 ----- ----- ----- Daily

1.42.14

Each batch or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

Each lot or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

Every 2 hours & after any change

1.42.143.71.4

2.143.7

Each batch (rotary furnaces only) or continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

Continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement

1.43.7

Dissociation of ammonia shall be checked in gas nitriding.

Each batch and every 4 hours minimum

1.43.7

Every 2 hours minimum

1.42.143.13

Check salt chemistry (soluble oxides) in salt baths used for austenitizing, or decarburization on the parts.








Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

B3.7 Quench Media Process Parameters- Temperature -----

- Quench Level Daily Daily ----- Daily- Agitation ----- Daily

B3.8 Monitor time in furnace, cycle time or belt speed. Each batch ----- Each batch

B3.9 Each batch ----- Each batch

B3.10 Each batch ----- Each batch

4.0 IN-PROCESS/FINAL TEST FREQUENCIES B4.1 Microstructure Daily per furnace -----

B4.2 Surface hardness Each batch ----- Each batch

B4.3 Core hardness (when specified) Each batch Every 4 hours ----- Each batch

B4.4 Case depth (when specified) Each batch Every 4 hours ----- Each batch

1.42.12 Each batch or

continuous recording with sign-off every 2 hours. Alarm systems satisfy the sign-off requirement.



- Daily - Monitor each load in the absence of an alarm system.

- Daily - Monitor every 2 hours in the absence of an alarm system.

1.42.14


1.42.7

Monitor load size or fixturing or loading rate as applicable.


1.42.12

Quench Delay Time if applicable -Alarm system shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.

Each basket if applicable.

1.42.15

Daily per furnace

Daily per furnace

1.42.15

Every 2 hours minimum

1.42.151.4

2.15








Related HTSA

Question #

Batch Furnace

ContinuousFurnace*

5.0

Quench Media Controls If ApplicableB5.1 Polymer Quench Media

- Concentration Daily Daily ----- -----Every six months ----- -----

B5.2 Water Quench Media- Suspended solids Every six months ----- -----

B5.3 Salt Quench Media- Analysis & Contaminants Every six months -----

B5.4 Brine or Caustic Quench Media Daily Daily ----- -----

- Suspended solids Every six months ----- -----

B5.5 Oil Quench MediaQuarterly Quarterly ----- -----

B5.6 2.13 Rust Preventive - Soluble Oil- Concentration 2x / week 2x / week ----- 2x / week

B5.7 2.11 Washers- Concentration of cleaner Daily Daily ----- Daily

Each shift Each shift ----- Each shift

QUENCHANT AND SOLUTION TEST FREQUENCIES

2.123.14

- Quenchability Check; e.g., cooling curve, viscosity, or titration.

Every six months

2.123.14 Every six

months2.123.14 Every six

monthsEvery six months

2.123.14 - Concentration and/or Specific

GravityEvery six months

2.123.14 - Water content, suspended solids,

viscosity, cooling curve, total acid, and flash point.




Item # Category/Process Steps

1.0

C1.1 Yes Yes Yes

C1.2 Yes Yes

C1.3 2.16 ----- ----- -----

C1.4 3.2 Yes Yes Yes

C1.5 3.2 ----- ----- -----

PROCESS TABLE C - Aluminum Heat Treating



*Continuous furnace frequencies are per lot (work order) or as specified, whichever is more frequent.----- indicate "not applicable".

Related HTSA

Question #

Batch Solution Treating and Aging Furnaces

Continuous Solution Treating and Aging

Furnaces

Annealing Furnace


3.13.7

All furnaces and quench systems shall have temperature indicating instruments.

3.13.7

Continuous strip charts and/or data loggers are required for temperature sensors.

Yes











Related HTSA

Question #



Furnaces

Annealing Furnace

2.0 PYROMETRY C2.1 Yes Yes Yes

C2.2 Yes Yes Yes

C2.3 Yes Yes Yes

3.23.3


3.23.3



3.23.3



(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the last temperature uniformity survey; this checked shall be performed weekly.



Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed bi-annually every two years at a minimum.









Related HTSA

Question #



Furnaces

Annealing Furnace

C2.4 3.4 Yes Yes

C2.5 3.5 Yes -----

C2.6 3.5 ----- ----- Yes

C2.7 3.2

Temperature Uniformity Survey (TUS): refer to AMS 2750D for procedures. TUS frequency shall be quarterly and after major rebuild.

Temperature uniformity tolerance for solution treating and aging furnaces shall be +/- 6 C (or +/- 10 F). Temperature uniformity tolerance for annealing furnaces shall be +/- 14 C (or +/- 25 F).















Related HTSA

Question #



Furnaces

Annealing Furnace

3.0 PROCESS MONITOR FREQUENCIESC3.1 Monitor primary temperature control instrument(s).

C3.2 Quench Media Process Parameters-----

- Quench Level Daily Daily ------ Agitation -----

C3.3 Monitor process cycle time Each batch Each batch

C3.4 Monitor load size or fixturing as applicable. Each batch Each batch

C3.5 Each batch Each load -----

4.0 IN-PROCESS/FINAL TEST FREQUENCIES C4.1 Hardness or tensile testing (post aging). Each batch Every 4 hours

5.0

C5.1 Polymer Quench Media- Concentration Daily Daily ------ Suspended solids Every six months Every six months -----

Every six months Every six months -----

C5.2 Water Quench Media- Suspended solids Every six months Every six months -----

C5.3 2.11 Washers- Concentration of cleaner Daily Daily Daily

Each shift Each shift Each shift

1.42.14




1.42.12 - Heat treater shall specify temperature range based

on product form and material. Temperature shall be monitored as noted.




- Monitor each load in the absence of an alarm system.


- Monitor every 2 hours in the absence of an alarm system.

1.42.14

Twice/shift & after any change in the indexing speed.

1.42.7


1.42.12

Quench Delay Time -Quench delay time shall be based on the time that the load exits the furnace to the time the load is at the bottom of the quench tank.

1.42.15

Each batch or every 4 hours for continuous furnaces


2.123.14

- Quenchability Check; e.g., cooling curve, viscosity, or titration.

2.123.14




Item # Category/Process Steps Per Coil

1.0

D1.1 --- Per customer requirementD1.2 2.16 -----

D1.3 2.16 -----

D1.4 3.2 -----

PROCESS TABLE D - Induction Heat Treating


The customer may have additional requirements, e.g., inspection testing, greater frequencies, etc. When performing the job audit, the auditor shall verify heat treater is conforming to the customer's requirements.----- indicate "not applicable".




Files shall be verified daily (or prior to use) with provers per SAE J864.Refractometers (typically used to check polymer quenchants and washer solutions) shall be verified each shift (with distilled water) and calibrated annually (per manufacturer's requirements) at a minimum.








2.0 PYROMETRY D2.1 3.2 -----

3.0 PROCESS MONITORING FREQUENCIES

D3.1 Quench Media Process Parameters- Temperature

- Quench Level Daily- Quench Pressure and Flow

D3.2 Monitor cycle time

D3.3


All process parameters shall be checked the beginning of every shift, tool change, or any equipment repair. In absence of process parameter alarms, also check process parameters at end of shift or lot (whichever is the greater frequency).

1.42.12 Alarm system for high and low

temperature is required.

- Quench pressure and flow may checked at manifold. Quench flow shall be checked visually at each coil.- In the absence of an alarm system, monitor every 2 hours or after any change.

1.42.14

Check cycle time at start up and after any process change.

1.42.143.16

Monitor: 1) Volts or Amps, and2) KilowattsUse of an energy monitor or signature monitor satisfies 1) and 2).

- This requirement applies to each power supply (not per coil). - In the absence of an alarm system, monitor every 2 hours or after any change.








4.0

D4.4 Induction pattern length

D4.5 Total or Effective Case depth

D4.6 Surface hardness

D4.7 Core hardness (when specified)

D4.8 Microstructure

IN-PROCESS/FINAL TEST FREQUENCIES

Production Setup or Coil Change - Per Coil(1st Piece Inspection)

1.42.15

1 part at start-up, end of production run, and every 4 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)

1.42.15

1 part at start-up, end of production run, and 1 part per 8 hours minimum, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)

1.42.15


1.42.15


1.42.15

1 part at start-up, and 1 part pre and 1 part post tool change, equipment repair, station alarm (shutdown, malfunction, etc.)








5.0

Quench Media Controls If ApplicableD5.1 Polymer Quench Media

- Concentration Once per dayMonthly

D5.2 Water Quench Media- Suspended solids Quarterly

D5.3 Brine or Caustic Quench MediaMonthly

- Suspended solids QuarterlyD5.4 2.13 Rust Preventive - Soluble Oil

- Concentration 2x / weekD5.5 2.11 Washers

- Concentration of cleaner DailyEach shift


2.123.14

- Quenchability Check; e.g., cooling curve, viscosity, or titration

2.123.142.123.14 - Concentration and/or Specific

Gravity





1.0 PROCESS AND TEST EQUIPMENT REQUIREMENTS

E1.1 Yes Yes Yes

E1.2 Yes Yes

E1.3 3.2 Yes Yes -----

E1.4 3.2 ----- ----- -----

E1.5 3.2 ----- ----- -----

E1.6 3.2 ----- ----- -----

E1.7 3.2 Yes Yes Yes

E1.8 2.16 ----- ----- -----

PROCESS TABLE E - Annealing / Normalizing / Stress-Relieving





Batch Furnace

ContinuousFurnace *

3.13.7

All furnaces, generators and quench systems (where applicable) shall have temperature indicating instruments.

3.13.7


Yes


Dew pointers, 3-gas analyzers, spectrometers, and carbon IR combustion analyzers (shim stock analysis), used to verify carbon potential in furnaces, shall be calibrated annually at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.

Verification of calibration of spectrometers, and carbon IR combustion analyzers, shall be checked daily or prior to use. This is applicable when used in controlling carbon-bearing atmospheres.

Verification of calibration of 3-gas analyzers with zero gas and span gas shall be performed weekly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.

Oxygen probe controllers shall be calibrated quarterly at a minimum. This is applicable when used in controlling carbon-bearing atmospheres.










Batch Furnace

ContinuousFurnace *

2.0 PYROMETRY

E2.1 Yes Yes Yes

E2.2 Yes Yes Yes

E2.3 Yes Yes Yes

3.23.3


3.23.3



3.23.3



(2) The relationship between the CTS and R-T/C at the operating temperature range shall be within +/- 1C (or +/- 2F) of their relationship determined at the time of the most recent temperature uniformity survey; this checked shall be performed weekly.



Type R and S thermocouples shall be checked monthly for equipment operating at or above 760C (1400F) and changed bi-annually every two years at a minimum.










Batch Furnace

ContinuousFurnace *

E2.4 3.4 Yes -----

E2.5 3.5 Yes -----


Temperature uniformity tolerance for hardening furnaces shall be +/- 14 C (or +/- 25 F). Temperature uniformity tolerance for tempering furnaces shall be +/- 11 C (or +/- 20 F).














Batch Furnace

ContinuousFurnace *

3.0 PROCESS MONITOR FREQUENCIES

E3.1 Monitor primary temperature control instrument(s). Each Shift

E3.2 Monitor generator atmospheres ----- ----- Continuous

E3.3 Monitor primary furnace atmosphere control(s)**. -----

E3.4 Daily Daily Daily

E3.5 Daily Daily -----

E3.6 Monitor time in furnace, cycle time or belt speed. Each batch -----

E3.7 Each batch -----

4.0 IN-PROCESS/FINAL TEST FREQUENCIES

E4.1 Microstructure (when specified) Daily per furnace Daily per furnace -----

E4.2 Surface hardness (when specified) Each batch Every 2 hours minimum -----

E4.3 Core hardness (when specified) Each batch Every 4 hours -----

5.0 SOLUTION TEST FREQUENCIES

E5.1 2.13 Rust Preventive - Soluble Oil

- Concentration 2x / week 2x / week -----

E5.2 2.11 Washers

- Concentration of cleaner Daily Daily -----

Each shift Each shift -----

1.42.14



1.42.143.7

1.42.143.7



1.42.143.7

Verify primary atmosphere control method by back-up method**.

1.42.143.13

For salt baths: check salt chemistry (soluble oxides) in salt baths or decarburization on the parts.

1.42.14


1.42.7

Monitor load size or fixturing or loading rate as applicable.


1.42.15

1.42.15

1.42.15


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